Aphena Pharma’s Solid Dose Division Expansion, Cookeville, Tennessee

Aphena Pharma Solutions announced the expansion of its Solid Dose Division in Cookeville, Tennessee, US in September 2020.

Project Type

Solid Dose Division expansion


Cookeville, Tennessee, US

Estimated Investment



September 2020


Aphena Pharma Solutions announced the expansion of its Solid Dose Division in Cookeville, Tennessee, US in September 2020.

The project will expand the company’s operations into biologics, cold chain storage and third-party logistics distribution. The company’s future headquarters will also be located in the facility.

Aphena’s Solid Dose Division expansion along with the recent expansion in its Liquids Division in Maryland will strengthen the company’s position as one of the most diversified manufacturing and packaging firms in the pharmaceutical industry. It will also enhance the company’s project capabilities at every level to better serve the customers.

Estimated to involve an investment of $21m, the expansion of the Solid Dose Division is scheduled for completion by February 2021.

Aphena’s Solid Dose Division expansion

Solid Dose Division is being expanded with the renovation of a newly acquired 500,000ft2 FDA packaging and manufacturing facility into a state-of-the-art pharmaceutical packaging and distribution facility.

The new facility will add approximately 258,000ft2 area to the company’s existing 578,000ft2 space in Cookeville.

It will be equipped with 24 high-speed bottling lines and eight thermoform blister packaging lines. It will have a cold chain storage capacity of more than 12,000 pallets. Furthermore, the facility will feature warehouse space of more than 200,000ft2, which will support new third-party logistics programme for the existing and future clients.

Aphena earlier increased the facility’s bottling capability with the addition of a new, state-of-the-art, high-speed, solid-dose bottling line with an integrated cartoner in February 2020.

The new bottling line is dedicated to the packaging of solid dose over-the-counter (OTC) and prescription products in branded and private label categories. The line will create an additional capacity of approximately 15 to 20 million bottles a year, which will allow the company to maintain a 50% capacity level for any upcoming projects or accelerate the capacity requirements.

Details of Aphena’s Solid Dose Division in Tennessee

Aphena’s solid and semi-solid dose packaging facilities at Tennessee extend across 578,000ft2 and offer packaging services, including bottle filling (glass & plastic), vial labelling and serialisation, cartoning, blister packaging (cold-form and thermoform blisters), pouching or bagging, secondary or serialisation packaging, displays (PDQ), heat-seal or stretch-film cards, rework projects and kitting.

“Estimated to involve an investment of $21m, the expansion of the Solid Dose Division is scheduled for completion by February 2021.”

The division offers a range of packaging solutions for solid doses, including tablets, capsules, and soft gels. The solutions are assisted by comprehensive quality processes, committed project managers, customer service agents, and continuous development programmes.

Additional services offered by Aphena’s Solid Dose Division include graphic support, clinical services, stability packaging services, package design, materials recommendations, child-resistant packaging support, and trade and physician samples.

Marketing commentary on Aphena Pharma Solutions

Aphena Pharma Solutions offers a range of pharmaceutical packaging and manufacturing services for the pharmaceutical, medical device, and biological markets. In addition to the Solid Dose Division in Tennessee, the company has a Liquids & Topicals Division located in Easton, Maryland.

The expansion of the Maryland facility involves the installation of two additional pharmaceutical blending suites with separate air handling systems, and two state-of-the-art tri-mix blending tanks for handling small and large batches of speciality creams, gels and topical products.

The facilities have a total footprint of 762,000ft2 with 24-hour and six-days-per-week operations to provide industry-leading turnaround services and product launch capabilities. Both the facilities are US FDA and DEA-registered and are also compliant with the current good manufacturing practices (cGMP).

Aphena’s contract packaging and manufacturing solutions will enable its customers to launch their products in the market on time and on budget.

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